HNP-Mikrosysteme - Model MZR-2905 - Micro Annular Gear Pump - Manual

Operating manual for micro annular gear pump mzr-7208, mzr-7208X1 HNP Mikrosysteme GmbH Bleicherufer 25 D-19053 Schwerin Phone: 0385/52190-301 Fax: 0385/52190-333 E-mail: info@hnp-mikrosysteme.de http://www.hnp-mikrosysteme.de Last update: January 2016 Impressum Original instructions Copyright HNP Mikrosysteme GmbH Bleicherufer 25 D-19053 Schwerin All rights, including translation, reserved. Without prior explicit written permission of HNP Mikrosysteme GmbH no part of this manual may be, copied, reproduced or processed. This manual has been prepared with care. HNP Mikrosysteme does assume no liability for any errors in this manual and resulting consequences. Likewise, no liability is assumed direct or subsequent damages arising from an incorrect use of the devices. While using micro annular gear pumps, the relevant standards regarding the specifications of this manual have to be followed. Subject to change without notice. Contents Operating manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice i Contents 1 General Information 1 1.1 Use 1 1.2 Pump Model Designation 2 1.3 Technical data of the micro annular gear pump 3 1.4 Measurements and flow charts 4 1.5 Technical data of the standard motor 5 1.6 Technical data of the optional motor with analog hall sensors (option) 8 2 Safety 10 2.1 Safety symbols in this operating manual 10 2.2 Staff qualification and training 10 2.3 Safety-conscious work 10 2.4 Safety instructions for the operator 11 2.5 Safety instructions for maintenance, check and assembly of the pump 11 2.6 Unauthorized pump conversions and spare part manufacture 11 2.7 Improper modes of operation 12 2.8 General safety instructions 12 3 Transport and intermediate storage 13 3.1 Shipment of the pumps and protection measures 13 3.2 Transport 13 3.3 Intermediate storage 13 4 Description 14 4.1 Operating principle of the micro annular gear pump 14 4.2 Construction materials 16 4.3 Liquid supply 16 5 Optional modules 17 5.1 Fluidic seal module 18 5.2 Heat insulation module 21 5.3 Heating modules 22 5.3.1 Electric heating module 22 5.3.2 Fluidic heating- and cooling module 23 5.4 Heating device „JETmicro“ 24 5.5 Gas-tight seal module 25 6 System integration 26 6.1 Check before the first assembly 26 6.2 Mounting of the micro annular gear pump 26 6.3 Assembly of the fluid connection fittings for mzr-7208 27 6.4 Filter selection and use 30 Contents Operating manual mzr-7208, mzr-7208X1 ii Technical data subject to change without prior notice Last update: January 2016 7 Motion Controller 31 7.1 Operation with Controller S-HV 31 7.2 Operation with Controller S-HP-E 34 7.3 Operation with Controller S-BL (Option) 39 7.4 Operation with Controller S-HP (Option) 42 8 Software »Composer« and »Elmo Studio« (Option for S-HP-E) 52 8.1 Use application of CD 52 8.2 Creating a new application 53 8.3 Adjustment of controller parameter 56 8.4 Operation of micro annular gear pump with RS-232 interface 60 8.5 Operation of micro annular gear pump as stand alone application 61 8.6 Problems and their removal with controller S-HP-E 62 9 Start Up / Shut Down 45 9.1 Preparing for operation 45 9.2 Startup of the micro annular gear pump 45 9.3 Flushing procedure after use 45 9.4 Shutdown of the micro annular gear pump 47 9.4.1 Conservation 49 9.4.2 Dismantling of the system 50 9.5 Problem shooting 51 9.6 Return of the micro annular gear pump to the manufacturer 51 10 »Motion Manager« software 52 10.1 Direct drive control 63 10.2 Programming of the control 65 10.2.1 Transfer of a mcl file to the drive 65 11 Software »EPOS« (Option) 68 12 Accessories for microfluidic systems 70 13 Non-liability clause 70 14 Problems and their removal 71 15 EC Directive 73 15.1 Electromagnetic Compatibility (EMC) 74 15.1.1 EMC Directive and Standards 74 15.1.2 Information on use as intended 75 16 Declarations of conformity 77 17 Service, maintenance and warranty. 82 Contents Operating manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice i 18 Contact persons 83 19 Legal information 84 20 Safety information for the return of already employed micro annular gear pumps and components 85 20.1 General information 85 20.2 Declaration of liquids in contact with the micro annular gear pump 85 20.3 Shipment 85 21 Declaration of media in contact with the micro annular gear pump and its components 86 22 Supplement 87 1 General Information Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 1 1 General Information Please read the »manual for micro annular gear pump« carefully before initial operation of the pump. The manual for the controller have to be seen as part of the pump manual. For missing manuals please call your distributor or HNP Mikrosysteme directly. We like to draw your attention especially to the following safety instructions. 1.1 Use The micro annular gear pumps described in this manual are suitable for continuous delivery and discrete dosage of water, watery solutions, solvents, methanol, oils, lubricating liquids, paints and varnishes as well as many other liquids. If you intend to treat any aggressive, poisonous, or radioactive liquids, you must conform to safety measures as according to the regulations in force. Any project concerning handling of corrosive liquids should be previously discussed with the pump manufacturer. The micro annular gear pumps must not be used for invasive medical applications, in which the liquid having had contact with the pump is re-introduced to the body. Micro annular gear pumps exclusively are provided for use in the industrial area. A private use is excluded. The micro annular gear pumps must not be used in aircrafts and spacecrafts or other vehicles without prior consent of the manufacturer. Data concerning resistance of the pumps to the manipulated liquids have been elaborated according to the best of HNPM's knowledge. However, operating parameters varying from one application case to another, no warranty for this information can be given. Information given in this manual does not release the customer from the personal obligation to check the integrity, correct choice and suitability of the pump for the intended use. The use of the micro annular gear pumps should be conform with technical norms and regulations in force. If you wish to receive more information than comprised in this operating manual please contact directly HNP Mikrosysteme. 1 General Information Operation manual mzr-7208, mzr-7208X1 2 Technical data subject to change without prior notice Last update: January 2016 1.2 Pump Model Designation This manual is valid for the micro annular gear pump mzr-7208, manufactured after 2001 by HNP Mikrosysteme GmbH, Bleicherufer 25, 19053 Schwerin, Germany. The date of release of the present manual figures on the cover. 1 General Information Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 3 1.3 Technical data of the micro annular gear pump The following table shows the technical data of the micro annular gear pump head mzr-7208. Constructive Specifications Displacement volume 48 µl Measurements (L x W x H) 205 x 60 x 80 mm Weight approx. 1.5 kg Internal volume 525 µl Material case stainless steel 1.4435 (316L) Material rotor tungsten carbide Ni-based Material bearing tungsten carbide Ni-based Shaft seal graphite reinforced Teflon®, 316L Static seals FPM (Viton®), optional: EPDM, FFPM Fluid connections 1/8" NPT or M10x1 internal thread, lateral Technical data Flow rate 4.8 ... 288 ml/min ( = 17.2 l/h) Smallest dosage volume 5 µl Operating pressure range 0 – 30 bar (Viskosity 1 mPas) 0 – 120 bar mzr-7208X1 (Viskosity 16 mPas) 0 – 150 bar mzr-7208 (Viskosity 16 mPas) Max. inlet pressure 10 bar Viscosity range 0,3 – 50.000 mPas Precision < 1 % Pulsation 6 % (theoretical) Liquid temperature -5 … +60 °C (150 °C*) Ambient temperature -5 … +60 °C Store temperature range -5 … +40 °C caption: * Differing specifications on request table 1 Technical data of the micro annular gear pump head mzr-7208 Warning The material properties of a liquid (e.g. viscosity, lubricating property, particle content, corrosiveness) impacts the technical data and the lifetime of pumps. Under appropriate conditions the characteristic values may be increased or decreased. Warning If you intend to operate the pump out of the range of the above given specification, please consult the manufacturer. Modifications may be necessary to ensure successful operation. Otherwise the pump or the system may be damaged seriously. 1 General Information Operation manual mzr-7208, mzr-7208X1 4 Technical data subject to change without prior notice Last update: January 2016 1.4 Measurements and flow charts position ±5°1/8" NPT fluidconnectormounting4 x Ø 4,3 (55x45) figure 1 Measures of the micro annular gear pump mzr-7208 Liquid water Liquid oil 0501001502002503000 10 20 30Differential pressure [bar]Flow rate [ml/min]600050004000300020001000Speed [rpm]Viscosity 1 mPasLiquid water0501001502002503000 20 40 60 80Differential pressure [bar]Flow rate [ml/min]600050004000300020001000Speed [rpm]Viscosity 16 mPasLiquid oilfigure 2 Flow charts mzr-7208 1 General Information Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 5 1.5 Technical data of the standard motor The micro annular gear pump mzr-7208 is provided with an actuator equipped with a 2 pole brushless DC-motor. The DC motor uses a high dynamic and is recommended for programmed dosage operation of the micro annular gear pump. With a control unit it is possible to manage lower RPM ranges down to 10 RPM. The accuracy of dosage can be achieved better than 0.5 %. The connection of the motor to a control unit is simple. Data of capacity Nominal voltage 36 V DC Stall torque 191 mNm Max. continuous current 6,29 A Starting current approx. 15 A Assigned power rating 201 W terminal inductance, phase-phase 143 µH No load speed by 36 V 10450 rpm operation range 10 ... 6.000 rpm temperature range -30 ... +125 °C Protective class IP54 Male socket for motor windings Binder Series 623 Type: 99-4637-20-06 Female cable connector for motor windings Binder Series 623 Type: 99-4636-00-06 Male socket for Encoder/Hall sensor cable Lumberg Typ: SFV 120 Female cable connector for Encoder/Hall sensor Binder Series 423 Type: 99-5130-15-12 Length connection cable 3 m lengthening up to max. 10 m table 2 Technical data of the motor Encoder Max. voltage Vcc 5 VDC ± 10 % Number of channels 3 (A, B, I) Counts per revolution and channel 500 Output current max. 20 mA Phase shift ? (nominal) 90° Operating temperature range 0 ... +40°C table 3 Technical data encoder 1 General Information Operation manual mzr-7208, mzr-7208X1 6 Technical data subject to change without prior notice Last update: January 2016 pin Description 1 motor phase A 2 n.c. 3 motor phase B 4 n.c. 5 motor phase C 6 n.c. table 4 Pin configuration of the motor supply pin Description A Encoder voltage +5 V B Encoder/Hall sensor GND C Encoder channel A D Encoder channel A neg. E Encoder channel B F Encoder channel B neg. G Encoder channel I H Encoder channel I neg. J Hall sensor voltage +5 V K Hall sensor A L Hall sensor B M Hall sensor C table 5 Pin configuration of the motor connector (Encoder/Hall) wire colour Description brown motor phase A green motor phase B white motor phase C table 6 Motor cable 3 poles wire colour Description pin Controller S-HV red Encoder voltage +5 V 6 pink Hall sensors voltage +5 V 6 yellow Encoder channel B 7 green Encoder channel A 8 blue Encoder/Hall sensor GND 9 brown Hall sensor A 10 grey Hall sensor B 11 white Hall sensor C 12 black screen earth screw table 7 Encoder/Hall sensors cable 8 poles with controller S-HV The encoder channel A and B are change together on the controller S-HV 1 General Information Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 7 wire colour Description pin Controller S-HP red Encoder voltage +5 V 36 blue Encoder/Hall sensor GND 19 green Encoder channel A 33 black Encoder channel A neg. 16 yellow Encoder channel B 34 violet Encoder channel B neg. 17 grey/pink Encoder channel I 35 red/blue Encoder channel I neg. 18 pink Hall sensors voltage +5 V 11 brown Hall sensor A 9 grey Hall sensor B 6 white Hall sensor C 10 green/yellow screen earth screw table 8 Encoder/Hall sensors cable 12 poles with controller S-HP (option) 1 General Information Operation manual mzr-7208, mzr-7208X1 8 Technical data subject to change without prior notice Last update: January 2016 1.6 Technical data of the optional motor with analog hall sensors (option) The micro annular gear pump mzr-7208X1 can alternatively be driven with a brushless DC-motor with analog hall sensors. It is characterized by higher dimensions and a wider speed range, which covers entirely the speed range of the micro annular gear pump and shows a longer service life than a brushed DC-motor. Performance parameters Nominal voltage 36 V Max. continuous torque 191,9 mNm Power 201 W No-load speed at 9 V 10,450 rpm Max. continuous current 6.29 A Terminal resistance, phase-phase 0.445 ? Terminal inductance, phase-phase 143 µH Speed 1 – 6000 rpm Ambient temperature -30 … +125 °C Male socket for motor windings Binder Series 623 Type: 99-4637-20-06 Female cable connector for motor windings Binder Series 623 Type: 99-4636-00-06 Male socket for Hall sensor cable Lumberg Type: SFV 50/6 Female cable connector for Hall sensor Binder Serie 423 Type: 99-5114-09-05 Type of Hall effect sensor analog Length connection cable 2 m table 9 Technical data of the brushless DC-motor pin Description 1 motor phase A 2 n.c. 3 motor phase B 4 n.c. 5 motor phase C 6 n.c. table 10 Pin configuration of the motor supply wire colour Description brown motor phase A green motor phase B white motor phase C table 11 Cable 3 poles of the motor supply 1 General Information Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 9 pin Description A Hall sensor GND B Hall sensor sensor voltage +5 V C Hall sensor A D Hall sensor B E Hall sensor C ABCDE table 12 Pin configuration of the hall sensor connector wire colour Description blue Hall sensor GND red Hall sensor voltage +5 V brown Hall sensor A grey Hall sensor B white Hall sensor C table 13 Motor cable 3 poles Function Connection Color Hall sensor A green Phase A brown Hall sensor B blue Phase B orange Hall sensor C gray Phase C yellow Voltage +5 V red Mass GND black table 14 Pin configuration of the motor (cable version) Please notice that the brushless DC motors must imperatively be operated with an adapted control unit The micro annular gear pump mzr-7208 can be delivered for this purpose with optional control units S-BL. 2 Safety Operation manual mzr-7208, mzr-7208X1 10 Technical data subject to change without prior notice Last update: January 2016 2 Safety Comply with the general safety instructions listed in the safety section as well as with the special safety instructions listed under the other main sections. All legal and corporate safety instructions have to be obeyed. 2.1 Safety symbols in this operating manual Please comply not only with the general safety instructions listed below, but also with specific safety instructions mentioned in the following chapters. Non respect of the safety instructions marked with the following signs represents danger to people: Danger symbol High voltage symbol Safety symbol according to DIN 4844 – W9 Safety symbol according to DIN 4844 – W8 Non compliance with the safety instructions marked with the following sign: Warning represents a risk of damage to the micro annular gear pump. Operating instructions machined directly on the pump such as the indication of liquid input and output should be followed and kept in a clearly readable condition. 2.2 Staff qualification and training The staff operating, servicing, inspecting and assembling the pumps must evidence the appropriate qualification for these works. Areas of responsibility and competence as well as monitoring of the staff must be precisely regulated by the decision maker. If the personnel do not have the necessary knowledge, they must be trained and instructed accordingly. If necessary, this can be implemented by the supplier or the manufacturer on behalf of the operator. Furthermore, the operator in charge must ensure that the content of the present manual has been fully understood by the personnel. 2.3 Safety-conscious work The safety instructions listed in this operating manual, the applicable national regulations for accident prevents and all internal working, operating and safety regulations of the operator must be complied with. 2 Safety Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 11 2.4 Safety instructions for the operator The surface temperature of the motor under full load may exceed 60°C. If needed, this surface should be protected on site against contact in order to avoid skin burns. The drive should be protected against dust, water vapor condensation, humidity, splash water, aggressive gases and liquids. Please provide for adequate air ventilation and thus cooling of the motor. The micro annular gear pumps mzr-2905, mzr-4605 and mzr-7205 must not be used in areas exposed to explosion risks or in the proximity of inflammable gases and vapors. Possible leaks of dangerous liquids (for example from the shaft sealing) should be guided away in a way not to represent any danger for the personnel and the environment. The pump should be regularly checked for possible leakage. All legal requirements in this matter should be followed. The existing protections against contact for the moving parts of the pump (such as for example the coupling) must not be removed during operation. Take care that all risks resulting from the electric energy are excluded. (For details please refer to the instructions provided by the authorities in charge or your power supplier.) Warning Please insure, that the totality of the liquid supply accessories such as tubes, hoses, filters etc. are free from dust or dirt particles. Impurities such as metal, plastic or glass particles may impair or damage the pump leading to its failure. Warning Please, operate the pump with a filter featuring 10 µm or smaller pores. It will protect the pump. 2.5 Safety instructions for maintenance, check and assembly of the pump As a rule all maintenance work on the device should be performed when the device is at a standstill. The shutdown procedure described in this manual must be followed. Pumps delivering liquids hazardous to health must be decontaminated. Immediately after the work had been completed all safety equipment and protection measures should be applied. Before starting the operation, please take into notice the instructions listed in the chapter 6. Warning Should a malfunction of the pump occur, do not dismantle the pump on your own but contact one of HNP Mikrosysteme's service staff for professional assistance. 2.6 Unauthorized pump conversions and spare part manufacture Conversions or modification to the device are only permitted with prior consent of the manufacturer. Original spare parts and accessories authorized by the 2 Safety Operation manual mzr-7208, mzr-7208X1 12 Technical data subject to change without prior notice Last update: January 2016 manufacturer ensure safety. The use of other parts will annul the liability of the pump manufacturer for any resulting consequences. 2.7 Improper modes of operation The safety of operation of the delivered device can only be insured by correct use, as described in chapter 1. The limit values given in this manual must not be exceeded in any case. 2.8 General safety instructions Please observe the following safety instructions The pump may operate at high pressures. For this reason please use only the delivered accessories and ensure that the employed fittings and tubing have been prescribed and approved for these pressures. In order to decrease the pressure, provide the system with a pressure control valve directing the excess liquid to the storage tank or back to the suction side. In the case of blockage of the pressure side the operating pressure can multiply, this can lead to the damage of downstream components. At a standstill, the liquid may flow through the pump in the direction of the falling pressure. In order to avoid this unwanted movement, please integrate non-return valves (see accessories). Protect the micro annular gear pump and the electric drive against strokes and shocks. Under normal working conditions the shaft sealing rings integrated in the pump prevent the liquid from leaking out of the device. The micro annular gear pumps are "technically leak-proof" however not "hermetically sealed" which means it may occur that gases or liquids enter to or escape from the pump. The allowed operating parameters of the drive should not be exceeded. In particular an incorrect polarity setting of the supply voltage may lead to damage of the control unit. Warning Please insure, that the totality of the liquid supply accessories such as tubes, hoses, filters etc. are free from dust or dirt particles. Impurities such as metal, plastic or glass particles may impair or damage the pump leading to its failure. Warning Please operate the pump with a filter featuring 10 µm or smaller pores. It will protect the pump. 3 Transport and intermediate storage Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 13 3 Transport and intermediate storage 3.1 Shipment of the pumps and protection measures The pumps leaving the factory are secured against corrosion and shocks. The inlets and outlets of the pumps are protected with plastic plugs in order to prevent any foreign bodies from penetrating into the device. 3.2 Transport In order to avoid any damage related to transport, the package must be protected against shocks. HNP Mikrosysteme guarantees, that all goods leave the factory in the best condition. Any noticed damage should be reported to the concerned forwarding agent, authorized dealer or to HNP Mikrosysteme, as manufacturer. 3.3 Intermediate storage Following points concerning pump storage should be observed: ? Necessary conservation procedure (see also chapter 8.4.1) ? The protective plugs must be left screwed in ? The pump should not be stored in humid places ? For storage temperature - refer to chapter 1.3 of the present manual 4 Description Operation manual mzr-7208, mzr-7208X1 14 Technical data subject to change without prior notice Last update: January 2016 4 Description 4.1 Operating principle of the micro annular gear pump Micro annular gear pumps are positive displacement pumps. They contain two rotors, bearing slightly eccentrically to each other; an externally toothed internal rotor and an annular, internally toothed external rotor (see figure 3). Due to their cycloid indenting, the rotors remain interlocked at any time, forming during rotation a system of several sealed pumping chambers. As the rotors revolve around their offset axis, the pumping chambers increase on the induction (suction) side and simultaneously decrease on the delivery side of the pump (see figure 4). A homogenous flow is generated between the kidney-like inlet and outlet. internalrotorexternalrotordelivery sideinduction sideinlet outlet figure 3 Principle of the micro annular gear pump figure 4 Operating principle of the micro annular gear pump In the case of rotary displacement pumps, the delivered amount of liquid may be easily calculated form the displacement volume Vg of the pump and the number of revolutions of the rotor n. Displacement volume stands for the volume of liquid that is moved within one revolution of the rotor. This relationship is illustrated by the following formula: nVQ gVol ??? ? The volumetric efficiency ?Vol shows the relationship between the actual and the theoretical flow rate. The existing differences result from internal movement of the liquid during the operation. 4 Description Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 15 Example: According to the formula mentioned above the mzr-7205 pump featuring a displacement volume of 48 µl delivers at 3000 rpm and with a volumetric efficiency of 100% 144 ml/min. The table 15 shows theoretical flow rate values depending on speed expressed in ml/min and ml/h. RPM Q [ml/min] Q [ml/h] 100 4.8 288 500 24 1,440 1000 48 2,880 2000 96 5,760 3000 144 8,640 4000 192 11,520 5000 240 14,400 6000 288 17,280 table 15 Theoretical flow rate of the micro annular gear pump mzr-7200 Pressure generated by the pump is determined by the configuration of the fluid delivery system and results from both the hydraulic pressure and the hydraulic resistance (tubing, narrow passes etc.). The volumetric efficiency of a pump decreases when the differential pressure rises. The viscosity of the manipulated liquid has an important impact on the volumetric efficiency. The volumetric efficiency increases for higher viscosity values because the internal leakage values go down. Cavitation is an effect which, starting form a certain limit speed value, may reduce the volumetric efficiency of a pump. In the case of highly viscous liquids this limit speed value is lower. That happens because of the liquid-specific drop of vapor pressure in the suction tube which leads to gas formation inside the pump. The particularity of the mzr-pumps is their highly precise construction, which provides for both high operating pressures and a high dosage precision. The gap between both rotors and between the rotors and the adjacent case parts lies in the range of a few micrometers. This precision is the key factor enabling to achieve volumetric efficiency close to 100%. 4 Description Operation manual mzr-7208, mzr-7208X1 16 Technical data subject to change without prior notice Last update: January 2016 4.2 Construction materials Wetted parts mzr-7208 Pump housing stainless steel 316 L (1.4404, 1.4435) Rotors, shaft, bearing tungsten carbide Ni-based Shaft sealing graphite-reinforced PTFE, 316L spring Static sealing FKM, optional: EPDM, FFKM table 16 Construction materials of the wetted parts The resistance of the construction materials to the delivered liquids should be verified by the operator for each individual application. Pumps handling non-lubricating liquids have shorter service lives. 4.3 Liquid supply mzr-7208 Liquid inlet/outlet lateral 1/8" NPT internal thread front 1/8" NPT internal thread optional: front connection M10 x 1.0 Tubing tube/hose OD 6 mm table 17 Liquid supply The suction side is indicated with the letter »S« the delivery side with the letter »D«. An arrow in the front of the pump indicates the operating direction of the shaft. In order to prevent foreign bodies from penetrating into the pump, the liquid inlet and outlet are protected with plastic plugs or screws. Please remove them before you assembly the pump. 5 Optional modules Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 17 5 Optional modules The spectrum of applications of the high performance micro annular gear pump series may be expanded by using different additional modules. The modules allow for special applications, which could otherwise not be accomplished with a standard pump version. The modules may be combined with each other and with almost all available pump heads and motor versions. ? Fluidic seal module prevents possible chemical reactions between the delivered liquid and the surrounding environment ? Thermal insulation module extends the operating temperature range of the pump by protecting the motor from overheating ? Heating module enables to regulate the temperature of the fluid-containing parts of the pump ? Gas-tight sealed version: almost hermetically sealed pump, delivered as standard with the high performance mzr-pumps The configuration of a given pump version should in each case be discussed with consideration to the specific requirements of the application. Additional customized modules may be designed on demand. 5 Optional modules Operation manual mzr-7208, mzr-7208X1 18 Technical data subject to change without prior notice Last update: January 2016 5.1 Fluidic seal module Fluidic seal moduleliquid outlet(delivery side)sealing liquidoutletsealing liquidinletliquid inlet(suction side) liquid supply tubecartridge figure 5 Layout of the micro annular gear pump with the fluidic seal module, example of mzr-4605 (the layout on the right: with the optional sealing liquid delivery set) The module can be applied for liquids which tend to react or crystallize in contact with gases such as oxygen or water. The use of a fluidic seal module has to be confirmed with the pump manufacturer. The function of the fluidic seal module The shaft sealing employed in the high performance micro annular gear pump is designed in a way that allows for the formation of a boundary layer in which the delivered liquid comes into contact with the surrounding environment. Small amounts of water vapor and oxygen may penetrate through the protective boundary liquid film into the pump. The fluidic seal module enables to control this influx - only a chosen and compatible liquid may come into contact with the delivered liquid. The fluidic seal module prevents also the inverse movement of the liquid - from the pump to the environment - which could otherwise not be excluded. With the fluidic seal module, a second sealing is added to the existing shaft sealing. A cylindrical chamber with input and output openings displaced by 180° is located between the two seals (see figure 6). When the chamber is filled with an appropriate sealing liquid, the manipulated liquid does not enter into contact with water vapor and oxygen, but dilutes at a small ratio in the sealing liquid. The dilution ratio depends on the existing pressure relations and drops with increasing viscosity. 5 Optional modules Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 19 fluidicseal moduleinlet seal liquidoutlet seal liquidoutlet pump liquidinlet pump liquidfluidicchambergas tight moduleadditionalshaft sealpump shaft shaft sealoutlet pump liquidinlet pump liquid figure 6 Pump head without the fluidic seal module Pump head with the fluidic seal module Pump operation with the fluidic seal module Only liquids compatible with the delivered liquid may be used as sealing liquids. That means no liquids that could possibly react with the delivered liquid should be employed. The composition of the sealing liquid should be determined by the operator. While filling up the fluidic seal chamber a particular attention should be paid to proper venting of the chamber through the two openings featuring a 1/4 - 28 UNF thread. These openings are slightly shifted downwards and upwards to facilitate the degassing of the sealing chamber (see figure 8). The chamber is filled through the bottom opening. The sealing liquid should be filled in so long, till it flows free of air bubbles out of the top opening. Now the inlet should be screwed down. Sealing liquid inletSealing liquid outlet figure 7 Sectional view of the fluidic seal module A cartridge may be used to supply the sealing liquid to the chamber (see figure 5). In special cases compressed air may be applied to the sealing liquid in order to enhance the sealing function. The sealing chamber may be flushed. Make sure that enough sealing liquid is supplied to the fluidic seal chamber in order to prevent any penetration of air and water vapor to the module. If the fluidic seal chamber is empty, the pump should immediately be stopped. Dry operation may lead to shaft seal damage. 5 Optional modules Operation manual mzr-7208, mzr-7208X1 20 Technical data subject to change without prior notice Last update: January 2016 In case the pump is not installed in the standard way (pump name read horizontally), it is possible to shift the outlet and inlet openings of the pump. However an appropriate supply of the sealing liquid should still be ensured and all presence of air bubbles within the fluidic seal chamber should be avoided. Use of the fluidic seal accessories The fluidic seal set is mounted at the bottom inlet (see figure 7). During assembly it is important to check if the ferrule is tightly attached to the tube and that the tube is tightly screwed to the inlet of the fluidic chamber. figure 8 Assembly of the fluidic seal accessories (standard version) Liquid supply set in stainless steel version (as separate accessory) Stainless steel liquid supply set is available on request. The use is the same as with the standard version. The liquid supply is done by a glass syringe. figure 9 Stainless steel set for the fluidic seal module 5 Optional modules Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 21 5.2 Heat insulation module The heat insulation module enables to deliver hot liquids up to temperatures of 150° C (302 °C). It comprises thermally insulating coupling components made of plastic (PEEK) located between the pump and the drive. The drive should not be exposed to overheating. For this reason the heat transfer from the pump to the drive should be limited. An additional thermal barrier is provided by the plastic motor housing. If the surrounding temperature rises, the pump is working over a longer period or the manipulated liquid features a high temperature, convection cooling of the motor is recommended. 5 Optional modules Operation manual mzr-7208, mzr-7208X1 22 Technical data subject to change without prior notice Last update: January 2016 5.3 Heating modules 5.3.1 Electric heating module The electric heating module enables active heating of the pump head up to 150° C (302 °C) operating temperature. The heating module consists of a heating jacket covering the pump head and a thermal element type J. Depending on the pump size, the thermal element will be integrated on the pump head in different ways. In order to adjust the temperature of the pump head, an additional heat regulating device may be delivered. Connection cable forelectric band heaterThermoelectric coupleElectric headingjacket figure 10 Micro annular gear pump mzr-2905 with the electric heating module Before connecting the heating jacket and the thermal element to the power supply, please observe the following technical data. Themal element Type MT-1.5 Thermal element Type J (Fe-CuNi IEC 584) alternativ: type L (Fe-CuNi DIN 43710) Temperature measuring range 0 to 400 °C Diameter of the sensing device 1.5 mm Material V4A (1.4541) Heating jacket mzr-2905/4605 mzr-7205 Voltage 230 VAC 230 VAC Power output 80 W 150 W Diameter 28 mm 35 mm Width 25 mm 25 mm table 18 Technical data of the electric heating module 5 Optional modules Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 23 5.3.2 Fluidic heating- and cooling module The fluidic heating and cooling module permits active heating or cooling of the pump head in the operating temperature range from -20 °C (-4 °F) to a maximum of 150 °C (302 °F). The module consists of a double casing covering the pump head and a thermoelectric couple type L, whose mode of integration varies depending on the pump size. Oil, water, superheated steam or adapted cooling liquids may be used as thermal liquids. If you are not sure, which heat transfer liquid is the best adapted in your case, HNP Mikrosysteme will help you find the suitable one. The thermal liquid ports 2 x G1/8" are displaced by 45°. The inlet for the heat transfer liquid is situated at the back (beveled) and the outlet is in the front (see figure 11). heat transfer liquidoutletthermoelectric coupledouble casingliquid inlet(suction side)heat transfer liquidinletliquid outlet(delivery side) figure 11 Micro annular gear pump with integrated fluidic heating- and cooling module (example of mzr-2905) This heating module is not certified for use in areas exposed to explosion hazards Before connecting the liquid supply, please observe the following technical data The maximal pressure of the heat transfer liquid should not exceed 20 bar. Thermal element Type MT-1.5 Thermal element Type J (Fe-CuNi IEC 584) alternativ: type L (Fe-CuNi DIN 43710) Temperature measuring range 0 to 400 °C Diameter of the sensing device 1.5 mm Material 1.4541 Double jacket mzr-7208 Length 45.5 mm Diameter 48.3 mm Double jacket material stainless steel 316L Inlet 2xG1/8“ (45° distance) Operating temperature range -20 to 150 °C Max. pressure max. 20 bar Flow rate max. 0.5 l/min table 19 Technical data of the heating and cooling module 5 Optional modules Operation manual mzr-7208, mzr-7208X1 24 Technical data subject to change without prior notice Last update: January 2016 5.4 Heating device „JETmicro“ The heating device „JETmicro“ has been designed for use with the electric heating module (see chapter 5.3.1). Hand: Blinks during temperature set in the manual input mode Ada: Ada display blinks during the automatic control adjustment AL: Alarm display – not configured, no importance Actual value display: = sensor failure = sensor reverse polarity With or the nominal temperature may be set. Power supply Shock-proof plug, 3 m long, 90-230 VAC Electrical connection 10-pole bush insert, 16 A/250 V Heating Sensor L N + - Zone 1 1 6 2 7 Zone 2 (Option) 4 9 5 10 table 20 Pin configuration of the heating device No importance Actual value Nominal value No importance Heating on Increase the temperature No importance Decrease the temperature 5 Optional modules Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 25 5.5 Gas-tight seal module Under normal operating conditions the sealing rings employed in the construction of the micro annular gear pump prevent the liquid from escaping out of the pump. The micro annular gear pumps are "technically tight" but not hermetically sealed, which means, it may occur that gases or liquids enter into or escape from the pump. In the case of a gas-tight version, the pump housing is sealed with supplementary rings. Used together with the gas-tight seal module and the fluidic seal module the pumps are almost perfectly hermetic. Up from March 2006 all micro annular gear pump mzr-7208 are delivered in a gas-tight version as a standard. 6 System integration Operation manual mzr-7208, mzr-7208X1 26 Technical data subject to change without prior notice Last update: January 2016 6 System integration 6.1 Check before the first assembly Inspect the pumps for potential damage during the shipment (see chapter 3.2). Please check, if the right pump type has been delivered, as according to the following points: ? Compatibility with the delivered liquid ? Viscosity range ? Pump performance (displacement volume, dosage volumes, operating pressures) ? Operating temperature range If you notice any difference between the required and the delivered pump type, please contact HNP Mikrosysteme. Do not put the pump into operation without prior approval. 6.2 Mounting of the micro annular gear pump Mounting of the micro annular gear pump head to an actuator Mounting of the micro annular gear pump head is done by stainless steel M4 screws on the front side flange of the actuator. If you should assemble your own actuator, please pay attention to the fact that axial forces may not occur by this actuator. The misalignment of the bore holes of the counterbalanced shaft coupling may not exceed 1/100 mm. Mounting of the micro annular gear pump The mounting angle of the micro annular gear pump can be fixed with four M4 screws. The preferential position of the pump is horizontal. If the pump has to be operated vertically, the position of the motor must be above the pump head in order to prevent liquid from entering into the motor. Warning Install the pump in such a way that in case of a failure no liquid can enter the motor or controller. Take precautions for the case of a leakage in order to prevent damage of nearby objects and the environment. The motor have to be protected from damp and dust. 6 System integration Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 27 6.3 Assembly of the fluid connection fittings for mzr-7208 The micro annular gear pump mzr-7208 is available in two versions. The liquid supply openings may be lateral or front with a 1/8" NPT thread screw. Pump heads equipped with the heating module are available with front liquid ports only. Alternative we can deliver the front fluid supply connection M10x1 or M12x1. Lateral screw connection 1/8" NPT figure 12 Fluid connection fitting 1/8" NPT, stainless steel 1. The thread of the fitting should be wrapped with 2-3 layers of PTFE tape and screwed in the NPT thread (see table 21). First manually, then tightened with ½ to ¾ wrench turns. 6 System integration Operation manual mzr-7208, mzr-7208X1 28 Technical data subject to change without prior notice Last update: January 2016 Clean the internal and external screw threads leaving no residues. Make sure the internal and external screw threads are not dented or deformed. Wrap the PTFE tape around the screw thread clockwise beginning with the second pitch of screw thread.. The PTFE tape should be wrapped tightly around the screw thread approx. two times (720°). Cut the PTFE tape off and wind the end of the tape tightly around the screw thread. The PTFE tape should not stick out over screw thread because pieces can be cut off and get into the system. table 21 Use of PTFE Tape 2. Cut the tube or hose to the right angle with an adapted hose cutter. Metal tubing, that produces swarf during cutting must be throughoutly cleansed and flushed. The smallest piece of swarf in the liquid delivery system may cause failure of the micro annular gear pump. 3. Screw the tube or hose (the latter always with a support tube) in the fluid inlet/outlet port of the pump first manually then tighten it with 1¼ wrench turns. During this operation use a second wrench to hold the hose against the bottom of the inlet/outlet port. 4. In order to avoid dry operation, provide for a sufficient liquid supply before each use. 6 System integration Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 29 Front fluid supply connection M10x1 figure 13 Fluid connection fitting M10x1, stainless steel 1. Cut the tube or hose to the right angle with an adapted hose cutter. Metal tubing, that produces swarf during cutting must be throughoutly cleansed and flushed. The smallest piece of swarf in the delivery system may cause failure of the micro annular gear pump. 2. Slide the pressure screw on the tube (the latter always with a metal support tube). 3. Slide on the clamping ring, bevel towards the end of the tube or hose. 4. Screw the tube or hose (the latter always with a metal support tube) in the liquid supply port first manually then tighten it with 1¼ wrench turns 5. In order to avoid dry operation, check before each use that enough liquid is supplied to the pump. Warning Dry operation of the micro annular gear pump may damage in particular the bearing and the sealing. However, a short dry working phase at the beginning of the operation is harmless. 6 System integration Operation manual mzr-7208, mzr-7208X1 30 Technical data subject to change without prior notice Last update: January 2016 6.4 Filter selection and use In majority of cases it is recommended to integrate a filter on the suction side of the micro annular gear pump to ensure its secure operation. The recommended filter pores or mesh size should not exceed 10 µm. The penetration of particles or swarf that could cause a blockage or damage to the pump can only be avoided by using an adapted filter. HNP Mikrosysteme offers a choice of standard filters covering a broad spectrum of applications. You may count on our assistance for the selection of the most suitable one. In order to select the best adapted filter, such operating parameters as flow rate, viscosity and degree of pollution of the liquid will be needed. An increase in at least one of the mentioned terms will require the use of a bigger filtering element or the pressurization of the delivered liquid. In case no suitable filter for high viscosity liquid can be found, it is possible to use a filter with slightly larger pore size. Prior discussion with HNP Mikrosysteme is here recommended. A filter with larger pores is still better than no filter at all. Alternatively an already filtered liquid may be used. Warning Because filters have a large internal volume, it is recommended to fill in the filter and the suction tube with already filtered liquid in order to avoid a longer dry operation of the pump during the startup. Warning Please control regularly the filtering elements for pollution. Cleanse regularly the filter or replace it with a new one. A polluted filter may considerably decrease the volumetric efficiency of a pump. Furthermore, because of the cavitation effects dosage imprecision and even pump damage may occur. Warning A too small filter (too little filtering surface) may considerably decrease the volumetric efficiency of the micro annular gear pump. What is more, because of the cavitation effects dosage imprecision and even pump damage may occur. 7 Motion Controller Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 31 7 Motion Controller Without a control unit you cannot start the micro annular gear pump mzr-7208 7.1 Operation with Controller S-HV We deliver the micro annular gear pump with the controller S-HV. Over this controller can be control the speed of the motor and the flow rate of the pump. Electrical parameter of the controller S-HV Power supply UB 24 (11 – 70) V Max. continuous Current Icont 6,28*) A Max. peak Current Imax 20*) A Velocity Range 50...6000*) rpm Inputs Set value Input resistor 20 k? Voltage signal ? 10 V Encoder signals Channel A, B Logic level TTL Frequency range max. 100 kHz Enable Logic level low 0...0,5/high 8...30 Enable high active Display 2-colour LED green: Ready, red: Error Outputs Current monitor „Monitor I“ Output voltage range ? 10 V proportional factor 0,5 V/A Output resistor 10 k? Speed monitor „monitor n“ Output voltage range ? 10 V proportional factor 0,5 V/A Output resistor 10 k? Supervision output Ready Input voltage range max. 30 V current < 20 mA Technical Data Temperature range operation -10 … +45 °C storage -10 … +80 °C Humidity range non condensing 20 … 80 % rel. hum. Dimensions L x B x H 180 x 100 x 40 mm *) Values are different for each pump type table 22 Technical Data of the controller S-HV 7 Motion Controller Operation manual mzr-7208, mzr-7208X1 32 Technical data subject to change without prior notice Last update: January 2016 Connector CReady/Error 21Monitor n 20Monitor I 19-Set Value 18+Set Value 17-15V, 20mA 16GND, Signal 15+15V,20mA 14Connector BEnable 13Hall C 12Hall B 11Hall A 10GND, Signal 9Encoder B 8Encoder A 7+5V,100mA 6Connector AGND, Power 5+Vcc 4Motor C 3Motor B 2Motor A 1Mpower supply 24 VDC/10A+-10 kOhmE231564choke coil module Figure 14 Connection plan with controller S-HV and micro annular gear pump mzr-7208 Initial operation procedure 1. Connect the motor cables with a motor control unit (see Figure 14). 2. Connect the supplied choke coil module in the lines of the motor winding. At low speeds or frequent stops the drive of the micro annular gear pump mzr-7208 can become hot By placing the choke coil module to the additional inductors in each phase of the motor winding, the heating of the actuator can be reduced. 3. Insert the jumper J2, J5, J6 and J7 for the encoder mode. 4. Connect the DC- power supply with 24 V to the control unit. Check for correct polarity. False connecting may cause severe malfunction or even destroy the electronic of the motor. 5. Check the adjustment of the internal potentiometer. 7 Motion Controller Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 33 potentiometer function potentiometer position P1 Gain course 5 % P2 Gain fine 0 % P3 maximum speed at set value of 10 V 100 % P4 Current limitation 60 % P5 Offset 50 % table 23 Internal potentiometer position 6. To avoid in any case dry running of the micro annular gear pump we recommend ensuring steady media supply. 7. Programming the control unit or turn the potentiometer in 0 position that the pump not rotate (0 rpm) 8. Switch on in the DC-power supply and start the micro annular gear pump. Notice: By an installation with the control unit SCA-B4-70-10 please read the operating instruction of the control unit The speed range can change with the jumper on the control unit. The motor of the micro annular gear pump mzr-7208 have 2 pole You can configure the control unit to control the speed with external potentiometer You can configure the control unit to control the speed with external potentiometer The speed range is to be set by jumper J10 and J11. One of four speed ranges is to be set. Jumper(s) max. speed J10 and J11 2500 rpm J10 5000 rpm J11 10000 rpm table 24 Speed range Skilled personnel may only do mounting and initial operating of micro annular gear pumps. Check for correct polarity. False connecting may cause severe malfunction or even destroy the electronic of the motor. Avoid in any case dry running of your micro annular gear pump as this may especially damage the seals. A short phase of dry running when setting the pump into operation is negligible. 7 Motion Controller Operation manual mzr-7208, mzr-7208X1 34 Technical data subject to change without prior notice Last update: January 2016 7.2 Operation with Controller S-HP-E We deliver the micro annular gear pump mzr-7208 with the controller S-HP-E. This programmable control unit enables to adjust speed for constant flow rates or the position of the motor for the dosage of constant amounts of liquid. Electrical parameter of the controller S-HP-E Power supply UB 48 (20 – 55) V Max. continuous Current Idauer 6*) mA Max. peak Current Imax 10 (< 1s)* ) mA Speed range 30...6,000*) rpm Max. motor power 800*) W Interface RS-232 after RS-232 standard 9600 Baud, 8 Bit, 1 Stop-Bit, RxD, TxD, GND (keine Handshake Signale) Interface CAN after DSP 301, DSP 402 Software Composer, Elmo Studio Input Digitale Eingänge programmable 10 Voltage signal 12 – 24 (High) V Analoge Eingänge Input resistor 2 programmable ± 10, 14 bit Auflösung V Encodersignale Voltage signal A, /A, B, /B, I, /I Channel max. 5 MHz Hallsignale Frequency range A, B, C Channel 0 – 1 (Low) 2,5 – 5 (high) V Output Digital output programmable 5 Voltage +5 V Encoder Voltage 5 V Max. Current 200 mA Voltage +5 V Hall sensors Voltage 5 V Max. Current 30 mA Voltage +5 V Auxiliary Voltage 5 V Max. Current 200 mA Technical Data Temperature range operation 0 … +40 °C storage -20 … +85 °C Humidity range non condensing 20 … 90 % rel. hum. Dimensions L x B x H 150 x 105 x 25.4 mm Weight IP20 Temperature range 640 g *) Values limited in the control unit with corresponding software table 25 Technical Data of the controller S-HP-E 7 Motion Controller Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 35 The control unit S-HP-E permits an easy startup of the pump with following interfaces: ? Power supply over connector ? Interface RS-232 over connector alternative CAN Bus over separate connector ? Prepared separate cable for the motor and the encoder/hall sensor with electrical connectors (useful for initial setup and an example for installation in control cabinet) ? Status display over LED. Warning When commissioning with the controller S-HP-E note the attached technical descriptions Warning Follow the enclosed instructions Warning Without a motion controller is the micro annular gear pump not set in operation Make sure that the polarity of the supplied direct current is correct, otherwise electronics will be damaged. figure 15 Connection plan with controller S-HP-E 7 Motion Controller Operation manual mzr-7208, mzr-7208X1 36 Technical data subject to change without prior notice Last update: January 2016 Initial operation 1. Connect the power cables with a motor control unit. figure 16 Connection plan power cable Connector Power & Motor S-HP-E Cable LIY(C)Y 3 x 1,5 mm² Description Connector 6 poles motor M1 brown Phase A 1 M2 green Phase B 3 M3 white Phase C 5 yellow/green screen table 26 Power cable figure 17 Connecting the power cable 7 Motion Controller Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 37 Connector Feedback S-HP-E PIN Feedback Cable CBL-DFDBK Cable LIY(C)Y 12 x 0,14 mm² Description Connector 12 poles motor 1 green white Hall sensor C M 10 yellow grey Hall sensor B L 2 pink brown Hall sensor A K 3 white blue GND B 4 brown red/pink +5 V (Hall/Encoder) A / J 5 orange black Encoder Channel A neg. D 6 light-blue green Encoder Channel A C 7 blue red/blue Encoder Channel I neg. H 8 red grey/pink Encoder Channel I G 14 black purple Encoder Channel B neg. F 15 purple yellow Encoder Channel B E grey n.c. no function n.c. table 27 Feedback Cable Connector J1 S-HP-E PIN Elmo I/O cable CBL-CELIO1 Signal Function 1 orange IN1 Programmable Input 1 2 light-blue IN2 Programmable Input 2 3 purple IN3 Programmable Input 3 8 black IN8 Programmable Input 8 4 grey OUT2 Programmable Output 2 5 pink OUT3 Programmable Output 3 6 blue IN4 Programmable Input 4 7 red IN7 Programmable Input 7 9 white / yellow INRET General Input Return 10 white / red OUTRET2-3 Programmable Output Return 2 + 3 11 yellow OUT4 Programmable Output 4 13 green OUT5 Programmable Output 5 12 white /black OUTRET4-5 Programmable Output Return 4 + 5 14 brown OUT1 Programmable Output 1 15 white OUTRET1 Programmable Output Return 1 Tabelle 1 I/O cable J1 2. Connect the RS-232 port of the controller with a free serial interface of a PC. For this purpose use the delivered adapter cable. 3. To avoid in any case dry running of the micro annular gear pump we recommend ensuring steady media supply. 4. Connect the power supply of 48 VDC on the connector Power & Motor. False connecting may cause severe malfunction or even destroy the 7 Motion Controller Operation manual mzr-7208, mzr-7208X1 38 Technical data subject to change without prior notice Last update: January 2016 electronic of the controller After switch on of the power supply during the initial phase of the S-HP-E the green LED "power" light on. figure 18 Main power supply connection diagram The power supply of the controller S-HP-E should be 48 VDC. With this power supply can be operated the micro annular gear pump with the entire speed range (see chapters 1.3 and 7.2). 5. You may now install the delivered software » Composer « as described in the chapter 9. Remarks: For problems with the initial operation read the included manual for detailed motion controller Further documentations are also located on the enclosed CD. 7 Motion Controller Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 39 7.3 Operation with Controller S-BL (Option) The micro annular gear pump mzr-7208 with brushless DC motor and analog hall sensors as drive be delivered with the S-BL control unit. This programmable control unit enables to adjust speed for constant flow rates or the position of the motor for the dosage of constant amounts of liquid. On the delivered diskettes or CDs you will find a PC-program operating under Windows that enables to program such parameters as speed, acceleration and current consumption. The delivery package comprises also a null-modem cable for connection to a serial interface of a PC. S-BL control unit Type of control unit 4-Q servo amplifier Nominal voltage U 24 V Power supply UB 12 - 30 V Residual ripple = 2 % Max. continuous output current Icontinuous 4500*) mA Max. peak output current Imax 6000*) mA Speed range 10...5900*) rpm Input No. 1 input resistance 5 k? Nominal analog speed voltage range ? 10 V Nominal digital speed PWM signal low 0...0.5 / high 4...30 V frequency range 100...2000 Hz Output/Input No. 2 Error state max. UB / 30 mA no error switched to GND programmed as input low 0...0.5 / high 3,5... UB V Input No. 3 TTL - logic level low 0...0.5 / high 3,5...30 V PLC - logic level low 0...7 / high 12,5...30 V Program memory 6,6 kBytes *) Values limited in the control unit with corresponding software table 28 Technical data of the S-ND control unit The control unit permits an easy startup of the pump with: ? the possibility to connect the voltage supply to the delivered DIN socket ? the possibility to connect the voltage supply with screw clamps ? a 8-pole screw clamps connector assembly for the motor cable ? speed set with potentiometer ? analog voltage signal 0-10 V for speed control at the screw clamps ? 9-pole connection plug for the RS-232 interface ? error output with status LED, programmable also as trigger input with screw connections ? tumbler switch S1 for the connection of digital input No. 3 of the motor control unit 7 Motion Controller Operation manual mzr-7208, mzr-7208X1 40 Technical data subject to change without prior notice Last update: January 2016 Startup of the micro annular gear pump with the S-BL control unit speed regulationserial interface of PC external voltage supply24 V DC / 5 ASmzr-pumpswitch S1 figure 19 Connection of the micro annular gear pump mzr-7208X1 and the S-BL control unit 1. Connect the motor cables to the connector of the S-BL control unit. The pin configuration is indicated in table 14. 2. Connect the RS-232 port of the MCBL3006 with a free serial interface of a PC. For this purpose use the delivered 9-pole null-modem cable. 3. Put the potentiometer of the S-BL control unit to zero position by turning it clockwise to the limit stop. 4. Connect the voltage supply 24 VDC. This can be done with the integrated DIN connector or, alternatively the 2-pole screw clamp (24 V = »+«; GND = »-«). Pay attention to the correct polarity. 5. You may now install the delivered software »Motion Manager« as described in the chapter 9. While connecting the DC voltage pay attention to the correct polarity, otherwise electronics may be damaged. 7 Motion Controller Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 41 Remarks: ? It is possible to adjust speed of the micro annular gear pump with the potentiometer without the need to connect the serial interface. ? With the analog nominal value input (connection clamps »AnIN« and »GND«) it is possible to adjust speed of the pump with a standard signal 0-10°V. For this purpose it is necessary to plug the jumper on the S-BL control unit from the »AnalogPoti« to the »AnalogExtern«. The serial interface does not need to be connected. ? In case of an overcurrent error the green status LED on the S-BL control unit turns red ? The standard programs memorized in the motor control unit may be started with the tumbler switch S1. Basic sample programs are shown in the chapter 9. For more advanced programs please refer to the user manual for Motion Controller MCBL3006. 7 Motion Controller Operation manual mzr-7208, mzr-7208X1 42 Technical data subject to change without prior notice Last update: January 2016 7.4 Operation with Controller S-HP (Option) We deliver the micro annular gear pump with the controller S-HP. Over this controller can be control the speed and the position of the motor for controlling of the flow rate and the dosage volume of the pump. Electrical parameter of the controller S-HP Power supply UB 24 (11 – 70) V Max. continuous Current Idauer 6,28*) A Max. peak Current Imax 20*) A Velocity Range 1...6000*) rpm Motor inductance (minimum) by (50 kHz) 100 µH Communication interfaces RS-232 9600 Baud CAN (CAN-Open) ISO/DIN 11898 Digital Inputs programmable 4 Voltage signal 13 - 30 V Input resistor 5 k? Digital Inputs for lim. sw., home position 3 Digital Outputs programmable 4 current < 500 mA Digital Output "ready" 1 current < 500 mA Auxiliary voltage output I/O 24 V Auxiliary voltage output for encoders Voltage signal 5 V current 100 mA Display Input + Output + Status 4 + 4 + 4 Operating system EPOS Microprocessor CPU MC 68332.25 MHz RAM SRAM 2 * 32 kB ROM EPROM 2 * 128 kB Technical Data Temperature range operation 0 … +40 °C storage - 20 … +85 °C Humidity range non condensing 20 … 80 % rel. hum. Dimensions L x B x H 190 x 100 x 40 mm Weight 900 g *) Values are different for each pump type table 29 Technical Data of the controller S-HP 7 Motion Controller Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 43 I/O Signals+24 V 45Input 4 25Input 3 42Input 2 24Input 1 41GND 19Encoder /I 18Encoder IEncoder /BEncoder B 34Encoder /A 16Encoder A 33+5V,100mA 36PowerGND, Power 5+Vcc 4Motor C 3Motor B 2Motor A 1M Power supply 24 VDC / 10A+-E1735+5 V 11Hall CHall BHall A 96HallsensorGNDI/O Signals710S4 S3 S2 S1231564choke coil module Figure 20 Connection plan with controller S-HP and micro annular gear pump mzr-7208 Initial operation procedure 1. Connect the motorcables with a motor control unit (see Figure 20). 2. Connect the RS232-Connector of the controller with a free serial interface of a PC. Here for use the 9-pin zero-modem cable, included in the delivery volume. 3. Connect the DC- power supply with 24 V to the control unit. Check for correct polarity. False connecting may cause severe malfunction or even destroy the electronic of the motor. 4. To avoid in any case dry running of the micro annular gear pump we recommend ensuring steady media supply. 5. Switch on in the DC-power supply and start the micro annular gear pump. 6. The micro annular gear pump can now be taken into service either by switching the switch S1 or by using the software »EPOS« delivered with (Installation see further down). 7 Motion Controller Operation manual mzr-7208, mzr-7208X1 44 Technical data subject to change without prior notice Last update: January 2016 The Controller S-HP is programming with the program »continuous_flowrate_7208.m« If you switch S1 the pump runs with approx. 3000 rpm and a flow rate of approx. 140 ml/min. If this parameter are not the best for the process, please change the parameter in the program Notice: Skilled personnel may only do mounting and initial operating of micro annular gear pumps. Check for correct polarity. False connecting may cause severe malfunction or even destroy the electronic of the motor. Avoid in any case dry running of your micro annular gear pump as this may especially damage the seals. A short phase of dry running when setting the pump into operation is negligible. 8 Start Up / Shut Down Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 45 8 Start Up / Shut Down 8.1 Preparing for operation After the liquid supply system had been completed, please check once again the operating conditions of the micro annular gear pump as according to the following points: ? Are the inlet and outlet tubes correctly connected? ? Is the entire liquid supply system clean - that means free of particles, foreign bodies, pollution or swarf? ? Has a filter been installed on the suction side? ? Has a sufficient amount of the right liquid been supplied? ? The pump does not run the risk of a longer dry operation? ? The entire liquid supply system has been checked for leakage? ? Is it possible to stop the pump by an emergency switch if an unexpected malfunction occurs at the startup? 8.2 Startup of the micro annular gear pump Switch on the voltage supply. The micro annular gear pump can now be put into operation by turning on the potentiometer knob or by sending a nominal external voltage signal. Start the filling in of the pump at low or middle speed (1000 - 3000 rpm). Warning Avoid dry operation of the pump over a longer time. The pump should be filled in before it is put to operation. 8.3 Flushing procedure after use After each service the micro annular gear pump should be carefully flushed with a non-corrosive, filtered and particle-free flushing liquid (see table 30 and table 31). During flushing procedure the pump should operate at a speed of about 3000 rpm and if possible against a low pressure (that can be obtained by using a restrictor, a capillary or similar). The flushing liquid must be compatible with the delivered liquid and suitable for solving the remaining liquid rests. Depending on the application for example water, or isopropanol may be used. If you have doubts whether a particular liquid is suitable for this function or not, please ask the manufacturer of the liquid or HNP Mikrosysteme. 8 Start Up / Shut Down Operation manual mzr-7208, mzr-7208X1 46 Technical data subject to change without prior notice Last update: January 2016 Flush the pumpSelection of flushing liquid (FL)Drain the pumpRight flushing liquidIs the pump resistant?nonoyesyesFlushing cycleEnd of flushing cycle figure 21 Diagram of the flushing procedure Warning Liquids that remain in the pump may crystallize, coagulate or lead to corrosion and as a consequence impair the work of the micro annular gear pump. Warning Please make sure that the pump components and particularly O-rings and sealing are resistant to the employed flushing liquid. (see table 31). Warning The flushing liquid (solvent) and the recommended duration of the flushing procedure depend on the delivered liquid (see table 31). The indicated flushing liquids are simple recommendations and should therefore be checked by the user as to their compatibility and suitability. Regulations concerning use of substances dangerous to health should be followed see table 31 (Resistance of the sealing material) see table 30 (Selection of the flushing liquid) see table 30 (Selection of the flushing liquid) 8 Start Up / Shut Down Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 47 Nature of the delivered liquid Flushing time [min] Suitable flushing liquid 1 Oils, fats, plastifierss 15-20 isopropanol, ethanol, acetone, benzine/petroleum ether 2 Solvents (polar + nonpolar) 5-10 isopropanol, ethanol 3 Other organic liquids 10-15 isopropanol , ethanol 4 Refrigerating and cooling agents 15-20 isopropanol, ethanol 5 Neutral water/y solutions 20-25 isopropanol, ethanol 6 Basic solutions 25-30 DI-water (deionized water) 7 Organic acids 30-40 isopropanol, ethanol 8 Weak mineral acids 25-30 DI- water 9 Strong mineral acids 35-45 DI- water 10 Strong oxidizing liquids 35-45 DI- water 11 Paints, varnishes, adhesives 50-60 not specified - for further information please contact HNP Mikrosysteme. table 30 Selection of the flushing liquid (solvent) and the duration of the flushing procedure depending on the delivered liquid. Warning Please make sure that the pump components and particularly O-rings and sealing are resistant to the employed flushing liquid (see table 31). Shaft sealing O-ring material Flushing liquid PTFE (Teflon®), graphite-reinforced UHMWPE FKM (Viton®) EPDM FFKM acetone 0 0 3 0 0 benzene 0 3 1 3 0 benzyl alcohol 0 - 0 2 0 butanol 0 - 1 0 0 dimethyl sulfoxide (DMSO) 0 0 3 0 0 ethanol 0 0 0 0 0 isopropanol 0 0 0 0 0 methanol 0 0 2 0 0 methylethylketone (MEK) 0 0 3 1 0 styrene 0 - 1 3 1 toluene 0 1 2 3 0 water 0 0 0 0 0 xylene 0 1 2 3 0 benzine/petroleum ether 0 0 0 3 0 oil / fine mechanics oil 0 0 0 3 0 Legend: 0 ... good suitability 1 ... suitability 2 ... conditional suitability 3 ... labile - ... not specified table 31 Resistance of the sealing materials depending on the flushing liquid (solvent) 8.4 Shutdown of the micro annular gear pump In order to shut down a mzr-pump the following steps should be followed: ? Flush the pump with a filtered and particle-free flushing liquid (solvent) as described in the chapter 8.3. ? After the flushing procedure decrease speed of the pump to 0 rpm 8 Start Up / Shut Down Operation manual mzr-7208, mzr-7208X1 48 Technical data subject to change without prior notice Last update: January 2016 ? Fill the pump with a suitable conservation liquid (see chapter 8.4.1) ? Remove the pump from the system (see chapter 8.4.2) By proceeding as shown in the diagram (see figure 23) you may prepare the pump for a longer standstill. LegendFL = flushing liquidCL = conservation liquidEnd of test/operationDrain the pump Pump requires flushing?Flushing cycleIs the pump clean?Selection of conservation liquid (CL)Delivery of solventsmanipulated liquid = conservation liquidFlush the pumpSelection of flushing liquid (FL)Drain the pumpRight flushing liquidIs the pump resistant?Selection of conservation liquid (CL)CLadequateIs the CL compatible with pumpIs the CL compatible with the last FL ? Nature of the CLLet the gas through the pump Fill in CLDesinstall the pumpClose the liquid portsEnd of conservation procedureNew operation after the conservation procedureliquidyesnononononononoyesyesyesyesyesyesgaseousnoyesFlushing cycleEnd of flushing cycleEnd of CL selection figure 22 Diagram of the shutdown procedure see table 30 see table 31 see table 32 see table 31 8 Start Up / Shut Down Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 49 8.4.1 Conservation If the micro annular gear pump operates at irregular intervals or for other reasons should be put out of operation for a longer period, it should, after service and flushing procedure (see chapter 8.3), be filled in with a suitable conservation liquid. The conservation liquid may be selected from the table 32 depending on the duration of the standstill and the resistance of the pump to the manipulated liquid. The indicated conservation liquids are simple recommendations and should therefore be checked by the user as to their compatibility and suitability. The figure 23 presents a diagram of conservation agent selection. Remark: This diagram is repeated as a part of the figure 22 (shutdown procedure of the micro annular gear pump). After the cleansing procedure the pump should be filled with a suitable conservation agent. You will find a choice of possible conservation agents in the table 32. Selection of conservation liquid (CL)CLadequateIs the CL compatible with pumpIs the CL compatible with the last FL ? yesnononoyesyesEnd of CL selection figure 23 Diagram - selection of conservation liquid (CL) see table 31 (Resistance of the sealing material) see table 32 (Selection of the conservation agent) 8 Start Up / Shut Down Operation manual mzr-7208, mzr-7208X1 50 Technical data subject to change without prior notice Last update: January 2016 Liquids Solubility in water Compatibility with the delivered liquid Duration of storage Breakaway torque Toxicology Viscosity Description isopropanol + + o o o + solvent for organic compounds, cosmetics, essential oils waxes, and esters, antifreezers, antiseptic agents acetone + + o o o + solvent for a number of organic compounds, unlimited solubility in water, dissolves natural and synthetic resins, fats, oils and commonly used plastifiers ethanol + + o o o + solvent for organic compounds, fats, oils and resins DI-water + + - - + + solvent for many organic and mineral liquids fine mechanics oil - - + + + + cleansing and protective action (dissolves fats, tar, rubber or adhesive substances, protects against corrosion). hydraulic oil - - + + + - lubricating and preserving properties (Warning: may resinate or deteriorate with time) nitrogen - + + + o + is not a solvent, may leave deposits after drying out air / compressed air + + + + + is not a solvent, may leave deposits after drying out Legend: + ... good/suitable o ... satisfactory; - ... bad/inadequate table 32 Selection of the conservation agent In order to prevent dust particles and foreign bodies from penetrating into the pump or the conservation agent from leaking out, please secure the liquid input and output openings with the delivered protective plugs or screws. Warning Water or DI-water should not be used as conservative liquids. They germinate already after a few days and build a biofilm which can later block the pump. 8.4.2 Dismantling of the system ? Put the drive out of operation by turning down speed to 0 rpm and by switching off the voltage supply. Make sure that the procedure described in the chapter 8.3 has been completed. ? Now that the pump has been stopped you may remove it from the system. ? Protect the inlet and outlet openings of the pump with adapted protective plugs or screws. 8 Start Up / Shut Down Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 51 8.5 Problem shooting If the pump stops operating abruptly or has difficulties with starting operation, please undertake the following steps: Try to liberate the micro annular gear pump: ? by turning the potentiometer knob back and forth or by connecting an analog voltage ? via the control software ? by pressing with a syringe a suitable flushing liquid (see table 30 and table 31) through the micro annular gear pump ? by changing the operating direction of the pump. If these measures turn out to be ineffective, please contact the service staff of HNP Mikrosysteme (see chapter ) and send the pump back to the manufacturer for inspection. Warning You should under no condition try to disassemble the pump by yourself. This may cause damage to the pump components and consequently annul your warranty claims. 8.6 Return of the micro annular gear pump to the manufacturer For the return of a micro annular gear pump and components that have already been employed, please follow the instructions: ? drain any remaining rests of the delivered liquid from the pump ? flush the pump with an adapted solvent ? remove the filter elements from integrated or loosely delivered filters ? protect all openings against dust with the delivered protective plugs or screws ? return the pump in its original packing The service personnel which carries out the repair should be informed about the condition of the already used micro annular gear pump. This is done by means of the "Declaration of media in contact with the micro annular gear pump and its components" (see chapter 21). This form may also be downloaded from the web site www.hnp-mikrosysteme.de/download. The "Declaration of liquids in contact with the micro annular gear pump and its components" must imperatively be filled in. The nature of liquid which entered into contact with the micro annular gear pump and its components must be specified. In case of non-compliance, the sender will be liable for any resulting injure to persons or any object damage. 9 Software »Composer« and »Elmo Studio« (Option for S-HP-E) Operation manual mzr-7208, mzr-7208X1 52 Technical data subject to change without prior notice Last update: January 2016 9 Software »Composer« and »Elmo Studio« (Option for S-HP-E) The » Composer « software enables operation and configuration of the drive and offers a possibility of an online graphic analysis of the operating data. The software is delivered on CD. The program may be installed on a PC running under Windows 2000®, Windows XP® and Vista® operating systems. Install the software » Composer « by starting the program »Setup« on the CD. After the installation the » Composer « program may be started from the folder from the Windows start menu. In order to program the drive the micro annular gear pump should be put into operation. The drive and the PC should be connected with the delivered "RS232-COM cable". All chapters described below are explained very detailed in the documentations of the controller manufacturer. 9.1 Use application of CD Load the application contained on the CD with the default parameters of the micro annular gear pump. Figure 24 Open Existing Application (Cello 15/60) or (Cello 10/100) The serial port RS-232 can change with button »Charge«. The communication opens via button "Download". The program in the EEPROM of the controller is deleted after a prior notice. 9 Software »Composer« and »Elmo Studio« (Option for S-HP-E) Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 53 Figure 25 Select Communication Type Figure 26 RS-232 interface properties 9.2 Creating a new application Following windows are to go through to create a new application. Figure 27 Welcome windows to Composer applications 9 Software »Composer« and »Elmo Studio« (Option for S-HP-E) Operation manual mzr-7208, mzr-7208X1 54 Technical data subject to change without prior notice Last update: January 2016 Figure 28 New Application name (Cello 15/60) or (Cello 10/100) Figure 29 Selection of the relevant interface Subsequently run the automatic scan of the serial port. Figure 30 Adjustment of the motor data 9 Software »Composer« and »Elmo Studio« (Option for S-HP-E) Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 55 Figure 31 Adjustment of the encoder data Figure 32 Adjustment of the driver parameter Figure 33 Adjustment of the digital inputs 9 Software »Composer« and »Elmo Studio« (Option for S-HP-E) Operation manual mzr-7208, mzr-7208X1 56 Technical data subject to change without prior notice Last update: January 2016 Figure 34 Adjustment of the digital outputs 9.3 Adjustment of controller parameter The controller parameters of the controller must be set for the operation of micro annular gear pump. If the controller settings are noted with an uneven running of the motor tuning of the controller, a further optimization will be carried out. The controller settings can be easily implemented on the following window. Figure 35 Adjustment of controller parameter 9 Software »Composer« and »Elmo Studio« (Option for S-HP-E) Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 57 Figure 36 Start Autotuning Figure 37 Start commutation test Figure 38 Advice turning the motor shaft Figure 39 Message with status 9 Software »Composer« and »Elmo Studio« (Option for S-HP-E) Operation manual mzr-7208, mzr-7208X1 58 Technical data subject to change without prior notice Last update: January 2016 Figure 40 Tuning parameter of velocity loop Figure 41 Windows scope motor velocity Figure 42 Advice window of motor rotation 9 Software »Composer« and »Elmo Studio« (Option for S-HP-E) Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 59 Figure 43 Tuning parameter of position loop Figure 44 Windows scope motor positioning Figure 45 Setup Information After adjustment of controller parameters, all parameters are saving with parameter/Save all parameters. 9 Software »Composer« and »Elmo Studio« (Option for S-HP-E) Operation manual mzr-7208, mzr-7208X1 60 Technical data subject to change without prior notice Last update: January 2016 9.4 Operation of micro annular gear pump with RS-232 interface In the velosity mode, the velocity of the pump motor speed is adjustable. An example for continuous delivery Command Description 1000 3000 0 Rotation speed of 1000 rpm Rotation speed of 3000 rpm Standstill of the pump (speed 0 rpm) Figure 46 Speed adjustment 9 Software »Composer« and »Elmo Studio« (Option for S-HP-E) Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 61 9.5 Operation of micro annular gear pump as stand alone application With the software "Elmo Studio" sequence programs are permanently save in the controller. The programs start automatically when the supply voltage. Figure 47 Software Elmo Studio Programming is described in detail in the documentation of the motion control manufacturer explained. Some example programs for dispensing with the micro annular gear pump are included on the CD 9 Software »Composer« and »Elmo Studio« (Option for S-HP-E) Operation manual mzr-7208, mzr-7208X1 62 Technical data subject to change without prior notice Last update: January 2016 9.6 Problems and their removal with controller S-HP-E Error Possible cause of error Action LED does not light up No power supply Check all power switches LED lights Motor does not rotate Using the software for error check of the controller Control is not responding Wrong interface Überprüfen, ob am PC die richtige Schnittsteller verwendet wird, ggf. umstecken oder EPOS die richtige Schnittstelle mitteilen wrong cable assignment Check the wiring, correct if necessary Motor hums whistles, or swinging Controller parameters are not optimal Controller parameters to check (see "Regulation tuning") in the separate manual control table 33 Excerpt error control S-HP-E If a disturbance that has not been mentioned in the above list, or that makes the use of the micro annular gear pump unsafe appears, please stop the operation of the pump without delay and contact the manufacturer. 10 »Motion Manager« software Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 63 10 »Motion Manager« software The »Motion Manager« software enables operation and configuration of the drive and offers a possibility of an online graphic analysis of the operating data. The software is delivered on CD. The program may be installed on a PC running under Windows 7®, Windows 8 or Windows 8.1® operating systems. Install the software »Motion Manager« by starting the program »Setup« from the CD. If the CD are not available you may still download this program from the web site http://www.hnp-mikrosysteme.de/download-center.html or the web site www.faulhaber.com (menu support - download). Here, the latest version is always available in English and German. After the installation the »Motion Manager« program may be loaded from the »Faulhaber Motors« folder from the Windows start menu. In order to program the drive, the micro annular gear pump should be put into operation. The drive should be connected to the PC with the delivered null-modem cable. 10.1 Direct drive control In the »Motion Manager« software the input commands may be sent directly to the drive. This enables to execute the movement commands and to modify the drive parameters. figure 48 Motion Manager software for direct control of the drive 10 »Motion Manager« software Operation manual mzr-7208, mzr-7208X1 64 Technical data subject to change without prior notice Last update: January 2016 The commands are entered in the field »Enter command:«. The button »Send« will send the command to the drive for execution (see figure 48). The commands may be given alternatively in capital letters or low case. The drive will ignore excess space characters. An example for continuous delivery Commands Description SOR0 V1000 V0 V6000 SOR1 Operating mode RS-232: Set the nominal speed via the RS-232 interface Rotation speed of 1000 rpm Standstill of the pump (speed 0 rpm) Speed value 6000 rpm Analog input of the operating mode: setup of the nominal speed with the potentiometer knob or by connecting an external voltage signal to the analog input An example for discrete dosage Command Description SOR0 LR10000 M LR20000 M SOR1 Operating mode RS-232: set the position via RS-232 interface Load a relative position of 10000 to the control unit 10,000 = 10 rotations (Remark: 1000 steps = 1 rotation) Execute the task / start positioning Load a relative position of 20000 to the control unit 20,000 = 20 rotations Execute the task / start positioning Analog input operating mode: Set nominal speed with potentiometer or by connecting a voltage signal to the analog input In case of the mzr-7208 micro annular gear pumps 1 revolution of the rotor corresponds to 1000 steps. The gear reduction is to be considered while using a gear reduction module. For more details concerning the operation of the Motion Manager, please read the online program help. 10 »Motion Manager« software Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 65 10.2 Programming of the control The control of the micro annular gear pump may be adapted by the user to a specific task by means of an easy programming language. The program files are available in the ASCII code and have by default the »mcl« extension which stands for "motion controller language". Various parameters of the drive such as the maximal speed, the acceleration, the number of rotations, the allowable current load and the parameters of the PI-controller may be programmed with this language. Furthermore, it is possible to program short movement sequences which will be saved in the internal memory of the drive and then autonomously executed. 10.2.1 Transfer of a mcl file to the drive The existing mcl files may be loaded to the file editor window using the menu command File - Open… (in the program window). figure 49 Menu file- open The required mcl file may be selected and loaded via the file selection window (see figure 49). By using the menu command Terminal - Transfer configuration file the mcl file will be transferred to the drive (see figure 50). 10 »Motion Manager« software Operation manual mzr-7208, mzr-7208X1 66 Technical data subject to change without prior notice Last update: January 2016 figure 50 Transfer of the mcl files as parameter data When a window appears with the enquiry if the mcl files should be transferred to the »Motion-Controller«, answer by clicking on the »Yes« button. In order to save the configuration and the programmed operation files in the EEPROM, confirm the dialogue window with »OK« (see figure 51). By this confirmation the program will be saved in the memory with a resident status and will be available for future operation. figure 51 Storage confirmation 10 »Motion Manager« software Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 67 A diskette with sample mcl programms is delivered along with the Motion Manager. At the delivery the pump has a standard program configuration. Moreover, a sample program that may be started with an external switch is available for discrete dosage tasks. Pump type Standard program Sample program for dosage tasks mzr-7208 mzr-7208_S.mcl switchdosage_7208_e3_S.mcl table 34 Overview of mcl sample programs 11 Software »EPOS« (Option) Operation manual mzr-7208, mzr-7208X1 68 Technical data subject to change without prior notice Last update: January 2016 11 Software »EPOS« (Option) For Windows® user we provide the E-Motion software EPOS 6.51 (see figure 52), a fully functional configurations and operations manager with online graphic performance analysis. Install the software » EPOS « of CD, included in the delivery volume. Installation of EPOS 1. Insert EPOS Installations CD 2. Select Windows » START -> run « 3. Enter " D:\\Einstall " ( D: drive unit stands for the CD-ROM ) and activate the installation with OK. Alternatively search the drive unit or directory that contains the installation file "Einstall.exe". 4. Follow the installation statements on the screen until the installation end is indicated. 5. This CD contains in addition a full illustrated installation statement in the PDF- format / Win200_Install_eng.PDF. At the finished installation of EPOS still a few simple operating system adaptations are necessary. figure 52 Software EPOS for motor control To use the EPOS-Software please read the Online-Help and the manual on CD. 11 Software »EPOS« (Option) Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 69 For stand-alone use without a PC the delivery volume contains a disk with m-files, which could be downloaded to the control unit and saved permanently to the EEPROM. 12 Accessories for microfluidic systems Operation manual mzr-7208, mzr-7208X1 70 Technical data subject to change without prior notice Last update: January 2016 12 Accessories for microfluidic systems The accessory range for the liquid delivery systems of HNP Mikrosysteme comprises complementary equipment such as hoses, tubes, fluid fittings, filters and non-return valves that are best adapted to your micro annular gear pump. We will eagerly share our long date experience as far as component selection is concerned. 13 Non-liability clause HNP Mikrosysteme GmbH shall not be liable any damage resulting form the non-respect of instructions comprised in this operating manual. It belongs to the user to check the integrity, the correct choice and the suitability of the product for the intended use. It remains at the responsibility of the user to conform to all laws, rules and regulations in force. This applies above all to the treatment of aggressive, poisonous, corrosive and other dangerous liquids. 14 Problems and their removal Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 71 14 Problems and their removal Error Possible cause of error Action 1 No function No power supply Check all power switches 2 Pump does not dose No dosage liquid in the tank Fill the liquid tank Motor error Check motor Status of the pump with the software Motion Manager Dosage needle blocked Check and clean the dosage needle Back-pressure valve does not work Check the back-pressure valve No signal for start dosage Check the start signal of the central control unit (PLC) Pump error Replace pump and send the pump to the manufacturer 3 Pump does not prime during bringing the dosage system into service Pump does not suck Check of the installation -„- Check air pressure on tank -„- Back-pressure valve does not open, Check the back-pressure valve -„- Air bubbles in fluid system (tubings, valves) Tubings leak Change the tubings 4 Motor works but pump does not pump No liquid in pump Prime the pump Air bubbles in fluid system (tubings, valves) Prime the pump and the fluid system Valve not open Flush the valve Dosage needle blocked Clean, flush or change the dosage needle Coupling of the connection motor –pump is loose Replace pump and send the pump to the manufacturer Pump shaft is broken Replace pump and send the pump to the manufacturer 5 Pump does not pump but is filled with liquid Particle in dosage liquid or pump blocked Check Status of the pump with the software Motion Manager Try to get free the pump with negative prime speed (-500 rpm) for only 1 s -„- Don’t change the parameter of the motor with command »FCONFIG«, »LPC«, »LCC« -„- Flush the pump with the syringe Back-pressure valve not open Flush the valve Dosage needle blockade Clean or flush the needle Air bubbles in fluid system (tubings, valves) Fill/Prime the pump and the fluid system 6 Dosage volume does not correspond with the datasheet or calculation Air bubbles in fluid system and pump Flush the fluid system and check the fluid system for opening connections Filter dirty Change the filter Back-pressure valve not open Flush the back-pressure valve 7 Liquid leaks out of the dosage needle (dosage needle drops) Back-pressure valve not closed Flush the back-pressure valve Pressure at process liquid tank Disconnect the pressure connection of the process liquid tank 8 Liquid leaks out of the sealing liquid needle Pressure at sealing liquid tank Disconnect the pressure connection of the sealing liquid tank 9 Dosage volume reduces over the time Filter dirty Change the filter Dirt or deposition in the pump Flush the pump or send the pump to the manufacturer for cleaning 10 Leak at the pump body Seal out of order Send the pump to inspection to the 14 Problems and their removal Operation manual mzr-7208, mzr-7208X1 72 Technical data subject to change without prior notice Last update: January 2016 Error Possible cause of error Action manufacturer 11 Leak of the fluid connections Flangeless ferrules leak Change the flangeless ferrules 12 Status of the pump cannot be checked or calibrated No contact/connection to the pump Check the power supply of the pump -„- Check the connection of the zero modem cable between PC and dosage system or try to use a new cable Motor control out of order Switch the power supply for a short time OFF and then ON to start the motor control again 13 Over temperature Pump surface dirty Clean the pump surface Pump works heavy Flush the pump 14 Over current Pump works heavy Dosage needle damage, replace the needle -„- Dosage needle blockade, clean or flush the needle Back-pressure valve not open Flush the back-pressure valve Particle in dosage liquid Flush the pump table 35 Trouble shooting guide If a disturbance that has not been mentioned in the above list, or that makes the use of the micro annular gear pump unsafe appears, please stop the operation of the pump without delay and contact the manufacturer. 15 EC Directive Operation manual mzr-7208, mzr-7208X1 Last update: January 2016 Technical data subject to change without prior notice. 73 15 EC Directive A Directive or EC Directive is a legal instrument of the European Community addressing at the member states and forcing them to implement specific regulations or targets. Leastwise, micro annular gear pumps are covered, by the scope of application of the following Directives: The following directives are of importance for the user of the described micro annular gear pumps: Low-Voltage Directive (2006/95/EC) The Low-Voltage Directive is not relevant for micro annular gear pumps described in this manual, because the supply voltage is limited to a maximum of 30 VDC. Machinery Directive (2006/42/EC) A micro annular gear pump is a machine and is consequently covered by this Directive. However, it may be a part of a machine or installation. EMC Directive (2004/108/EC) The Directive on Electromagnetic Compatibility (EMC) applies to all electronic and electrical devices, installations and systems. Consequently, the Motion Controller of the micro annular gear pump is covered by the EMC Directive. RoHS Directive (2011/65/EC) To our knowledge our products delivered to you do not contain substances or applications in concentrations that are forbidden by this directive. No sub